Meshing driven rollers of towel dispenser by closing loading door

ABSTRACT

A towel dispenser includes a main body; a loading door that rotates relative to the main body between open and closed positions; and a guide system that is configured to guide the toweling within the housing while towels are dispensed from the housing. The guide system includes a first roller attached to the main body and having a first toothed surface, and a second roller attached to the loading door and having a second toothed surface that is configured to mesh with the first toothed surface. The toothed surfaces of the first roller and the second roller mesh together when the loading door moves into the closed position from the open position and do not preclude the loading door from moving into the closed position from the open position.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a U.S. continuation patent application of,and claims priority under 35 U.S.C. §120 to, U.S. patent applicationSer. No. 12/861,804, filed Aug. 23, 2010, incorporated herein byreference, pending, which '804 application is a U.S.continuation-in-part patent application of, and claims priority under 35U.S.C. §120 to,

-   (a) international patent application serial number PCT/US10/37561,    filed in English on Jun. 6, 2010 and designating the United States    of America, pending, which international patent application is    incorporated herein by reference, and which international patent    application claims priority in the United States under 35 U.S.C.    §119(e) to each of,    -   (i) Troutman et al. U.S. provisional patent application Ser. No.        61/184,789, filed on Jun. 6, 2009, expired, which is        incorporated herein by reference, and    -   (ii) Troutman et al. U.S. provisional patent application Ser.        No. 61/266,169, expired, filed on Dec. 3, 2009, which is        incorporated herein by reference; and-   (b) U.S. patent application Ser. No. 12/795,384, filed Jun. 7, 2010,    incorporated herein by reference, abandoned,    -   (i) which '384 application is a U.S. continuation-in-part patent        application of, and claims priority under 35 U.S.C. §120 to,        international patent application serial number PCT/US10/37561,        filed in English on Jun. 6, 2010 and designating the United        States of America, pending, which international patent        application is incorporated herein by reference, and which        international patent application claims priority in the United        States under 35 U.S.C. §119(e) to each of,        -   (A) Troutman et al. U.S. provisional patent application Ser.            No. 61/184,789, filed on Jun. 6, 2009, expired, which is            incorporated herein by reference, and        -   (B) Troutman et al. U.S. provisional patent application Ser.            No. 61/266,169, filed on Dec. 3, 2009, expired, which is            incorporated herein by reference, and    -   (ii) which '384 application is a U.S. nonprovisional patent        application of, and claims priority under 35 U.S.C. §119(e) to,        each of        -   (A) Troutman et al. U.S. provisional patent application Ser.            No. 61/184,789, filed on Jun. 6, 2009, expired, which is            incorporated herein by reference, and        -   (B) Troutman et al. U.S. provisional patent application Ser.            No. 61/266,169, filed on Dec. 3, 2009, expired, which is            incorporated herein by reference.            Moreover, the Appendix hereto includes a copy of the            specification and drawings of the '169 provisional            application, which Appendix is incorporated herein by            reference. The present application further incorporates            herein by reference Troutman et al. U.S. patent application            publication number 2009/0065628, which published Mar. 12,            2009.

COPYRIGHT STATEMENT

All of the material in this patent document is subject to copyrightprotection under the copyright laws of the United States and othercountries. The copyright owner has no objection to the facsimilereproduction by anyone of the patent document or the patent disclosure,as it appears in official governmental records but, otherwise, all othercopyright rights whatsoever are reserved.

BACKGROUND OF THE INVENTION

The present invention generally relates to towel dispensers and, moreparticularly, to towel dispensers in which a length of toweling isextended from the housing for grasping and pulling by a user forseparation and dispensing of one or more towels. In preferredembodiments of the invention, the toweling comprises a roll ofperforated towels, in which the towels are connected together andseparable at perforation formed between the towels.

Towel dispensers are well known and generally include a housingconfigured to receive toweling; a guide system that defines a pathwithin the housing and that guides the toweling along the path duringmovement of the toweling while towels are dispensed; and a motor thatmoves the toweling along the path to the exterior of the housing,thereby exteriorly extending the toweling from the housing. The guidesystem can include rollers or fixed guides and typically includes one ormore driven rollers connected to the motor. A switch or sensor fordetecting motion or proximity of an object is provided to initiate theoperation of the motor. For example, in a known dispenser, a controlleris electrically connected to the sensor and is configured to activatethe motor when the sensor generates a signal that indicates the presenceof a hand.

Conventional towel dispensers also generally are configured to dispensetowels from continuous rolls of non-perforated toweling and include adevice for cutting the toweling to dispense individual towels. Thelength of the individual towels provided by the dispenser is determinedby the amount of time that the motor is operated or by measuring theindividual towel as it is dispensed, and such length generally ispreprogrammed into the dispensers such that the same length of towelingis automatically and consistently dispensed each time the hand-motionsensor is activated.

Conventional towel dispensers generally operate as follows. A roll oftoweling is placed within the housing and threaded through the guidesystem. A user causes a towel to be dispensed by placing a hand or otherobject near the sensor. Alternatively, the dispensing of toweling can beinitiated by pressing a button or switch that is configured to activatethe motor. Dispensing of the toweling is stopped when a predeterminedlength of toweling has been dispensed. Alternatively, in some cases thetoweling is stopped when the hand is removed or button/switch isreleased.

Conventional towel dispensers are disclosed in each of U.S. Pat. Nos.6,412,679; 6,419,136; 6,742,689; 6,745,927; 6,766,977; and 7,191,977.Each of these patents is incorporated herein by reference.

Even in view of known towel dispensers, it is believed that one or moreneeds exist for improved towel dispensers.

SUMMARY OF THE INVENTION

The present invention includes many aspects and features. Moreover,while many aspects and features relate to, and are described in, thecontext of toweling including a roll of sheet material separated byperforations that define towels when separated, the present invention isnot limited to use only in such context, and may be used with towelingthat does not include such perforations. Moreover, while preferredimplementations relate to dispensing of paper towels, the invention isnot limited to such implementations and is applicable, for example, inimplementations relating to the dispensing of toilet paper or othertypes of toweling.

Accordingly, in an aspect of the invention, a method of dispensingtowels from toweling with a dispenser includes: (a) using a motorassembly configured to cause a leading edge of the toweling to beextended from a housing of the dispenser and to cause the toweling to besubsequently retracted back into the housing, the step of extending thetoweling exterior of the housing for grasping by a user; and subsequentthereto, the steps of (b) the step of retracting the toweling into thehousing using the motor assembly; the step of sensing a leading edge ofthe toweling, using a sensor, while retracting the toweling; and thestep of ceasing retracting of the toweling into the housing using themotor assembly as a function of sensing the leading edge of the towelingusing the sensor. Moreover, it will be understood that reference to a“trailing edge” in the context of sensing an edge of the toweling duringretraction is, in fact, the “leading edge” of the toweling extending outof the housing. As such, it will be understood that in this context“trailing edge” and “leading edge” may be synonymous.

In a feature of this aspect, the housing includes a main body and aloading door. The loading door is configured to rotate relative to themain body between a closed position, in which the housing is configuredto extend toweling there from, and an open position, in which thehousing is configured to receive toweling therein. Furthermore, theloading door includes a towel carrier having a curved surface defining acavity within which toweling comprising a roll of paper towels isreceived and retained in floating engagement therewith. The roll ofpaper towels rolls and slides on the curved surface when unwindingduring said step of extending the toweling exterior of the housing forgrasping by a user. Moreover, the toweling gathers within the housingduring retracting of the toweling into the housing and does not windback onto the roll of paper towels. Preferably, the toweling buncheswithin the housing.

In another feature of the invention, the housing includes a main body, aloading door, and a guide system. The loading door is configured torotate relative to the main body between a closed position, in which thehousing is configured to extend toweling there from, and an openposition, in which the housing is configured to receive towelingtherein. The guide system is configured to guide the toweling within thehousing during extension from and retraction into the housing of thetoweling. The guide system includes a first roller attached to the mainbody and a second roller attached to the loading door. Moreover, thefirst roller preferably has a toothed surface that is configured to meshwith a toothed surface of the second roller. Furthermore, at least oneend of the first roller moves such that an axis of rotation of the firstroller moves relative to the main body of the housing. In this feature,the method further includes the step of moving the loading door into theclosed position after loading toweling within the dispenser, with thefirst roller being urged into engagement with the second roller when theloading door enters the closed position and the second roller acting onthe first roller so as to displace at least one end of the first rollerwhen the loading door enters the closed position.

In another feature, the housing includes extension walls locatedproximate opposite exterior sides of the housing that extend above a topside of the housing. In this feature, the method includes a preliminarystep of mounting the dispenser to the underside of a fixture, includingremoving a portion of each extension wall along a score line so as toadjust the distance from the underside of the fixture below which thetop side of the housing is mounted. In some embodiments including thisfeature, but not all such embodiments, the fixture is a cabinet mountedto a wall or suspended from a ceiling. In some embodiments includingthis feature, but not all such embodiments, the fixture is a shelf thatis mounted to a wall.

In another feature of this aspect, the toweling comprises a roll ofpaper towels and the dispenser is configured to unwind roll of papertowels during extension of toweling from the housing but not rewind theroll of paper towels during subsequent retraction of toweling into thehousing. Furthermore, a back side of the housing includes an openingthat is configured such that excess toweling gathering within thehousing may fall there through as a result of retraction of towelingback into the housing.

In another feature, the toweling comprises towels that are connectedtogether and that are separable at perforations formed there between. Inthis respect, the toweling preferably comprises a roll of perforatedpaper towels. The roll of paper towels generally may be any of thosecommercially available for consumer purchase, like those from companiessuch as Proctor & Gamble and Kimberly Clark. With further regard to thisfeature, the step of extending the toweling exterior of the housing forgrasping by the user further preferably includes extending a sufficientlength of the toweling such that at least one line of perforations islocated outside of the housing whereby tearing along the line ofperforations leaves a residual extent of the toweling extending outsideof the housing after tearing.

In another feature, the step of extending the toweling exterior of thehousing for grasping by the user comprises extending the toweling apredetermined unit length beyond the point at which the sensor detectsthe leading edge of the toweling. In some embodiments including thisfeature, but not all such embodiments, this includes extending thetoweling an extent that is less than the predetermined unit length suchthat at least one line of perforations is located outside of thehousing, whereby tearing along the line of perforations leaves aresidual extent of the toweling extending outside of the housing aftertearing; and may even include further extending the toweling anotherpredetermined unit length beyond the point at which the sensor detectsthe leading edge of the toweling. Furthermore, in at least someembodiments, the step of extending the toweling exterior of the housingfor grasping by the user may be performed in response to the sensing ofa hand proximate the dispenser.

With regard to this feature, the method in at least some embodiments,but not all, further includes setting the predetermined unit length, bywhich the toweling is extended, in a length learn sequence. The lengthlearn sequence preferably includes: (i) retracting the toweling until aleading edge of the toweling is sensed by the sensor; (ii) advancing thetoweling a preset extended length, the preset extended length beinggreater than at least a distance between immediately adjacent lines ofperforations in the toweling; (iii) retracting the toweling until aleading edge of the toweling is sensed by the sensor while measuring alength by which the toweling is retracted; and (iv) determining thedifference between the preset extended length and the measured retractedlength, the difference being the predetermined unit length. The presetextended length may be greater than twice the distance betweenimmediately adjacent lines of perforations in the toweling, whereby thepredetermined unit length may be set for dispensing up to two towels ata time; may be greater than three times the distance between immediatelyadjacent lines of perforations in the toweling, whereby thepredetermined unit length may be set for dispensing up to three towelsat a time; and may be greater than four times the distance betweenimmediately adjacent lines of perforations in the toweling, whereby thepredetermined unit length may be set for dispensing up to four towels ata time. The length learn sequence of the dispenser may be initiated byinstalling a roll of paper towels in the dispenser. This is preferablyaccomplished by moving a loading door of the dispenser, through which aroll of paper towels is received, to a closed position, with a length ofthe toweling preferably being draped over and extending from the loadingdoor.

In still another feature of this aspect, the motor assembly includes amotor and a controller that is configured to control operation of themotor and the subsequent extension of the toweling from and retractionof the toweling into the housing. With regard to this feature, themethod preferably includes the step of: measuring extension of thetoweling from the housing; measuring retraction of the toweling into thehousing; or both. In some embodiments including this feature, but notall such embodiments, such measuring is performed using an encoderpinwheel that rotates during extension and retraction of the toweling.In some embodiments including this feature, but not all suchembodiments, such measuring is performed using an LED component,complementary metal oxide semiconductor (CMOS) component, and digitalsignal processor (DSP) component; or a laser component, complementarymetal oxide semiconductor (CMOS) component, and digital signal processor(DSP) component. Moreover, the sensor for detecting the leading edge ofthe toweling may be comprised of the LED component, complementary metaloxide semiconductor (CMOS) component, and digital signal processor(DSP); or may be comprised of the laser component, complementary metaloxide semiconductor (CMOS) component, and digital signal processor (DSP)component.

In another feature, the loading door of the dispenser includes a guidingsurface along which toweling rides when retracted into the housing. Theguiding surface forms a backdrop that is dark and contrasts well withthe toweling so as to better define the leading edge of the toweling forsensing by the sensor.

In another aspect of the invention, a towel dispenser includes: ahousing for receiving toweling comprising a roll of paper towels; amotor assembly configured to cause a leading edge of the toweling to beextended from the housing and to cause the toweling to be retracted intothe housing after the leading edge has been extended; and a sensor forsensing a leading edge of the toweling during retraction of the towelingby the motor assembly. The sensor is configured to cause the motorassembly to cease retracting the toweling into the housing as a functionof the sensing of the leading edge of the toweling during retraction ofthe toweling into the housing.

In a feature of this aspect, the housing includes a main body and aloading door. The loading door is configured to rotate relative to themain body between a closed position, in which the housing is configuredto extend toweling there from, and an open position, in which thehousing is configured to receive toweling therein. The loading doorcomprises a towel carrier having a curved surface defining a cavityconfigured to receive the roll of paper towels in floating engagementtherewith such that the roll of paper towels rolls and slides on thecurved surface during unwinding.

In another feature of this aspect, the housing comprises a main body, aloading door, and a guide system. The loading door is configured torotate relative to the main body between a closed position, in which thehousing is configured to extend toweling there from, and an openposition, in which the housing is configured to receive towelingtherein. The guide system is configured to guide the toweling within thehousing during extension from and retraction into the housing of thetoweling, and includes a first roller attached to the main body andhaving a first toothed surface, and a second roller attached to theloading door and having a second toothed surface that is configured tomesh with the first toothed surface. At least one end of the firstroller moves such that an axis of rotation of the first roller movesrelative to the main body of the housing. Moreover, the first roller isspring biased toward engagement with the second roller when the loadingdoor is in the closed position, and the toothed surfaces of the firstroller and the second roller mesh together when the loading door movesinto the closed position from the open position and do not preclude theloading door from moving into the closed position from the openposition.

In another feature, the housing further comprises extension wallslocated proximate opposite exterior sides of the housing that extendsabove a top side of the housing. Each extension wall includes a weakenedline extending parallel to a weakened line of the other extension walls,whereby the extent above the top side at which each extension wallsextends may be changed. The extent represents a distance from theunderside of a cabinet below which the top side of the housing ismounted when the towel dispenser is installed under a cabinet. In someembodiments including this feature, but not all such embodiments, a backside of the housing includes an opening configured to permit excesstoweling to fall during retraction of the toweling back into thehousing.

In a feature, the motor assembly comprises a motor and a controllerconfigured to control operation of the motor and the subsequentextension of the toweling from and retraction of the toweling into thehousing.

In a feature, the motor assembly is configured to cause a line ofperforations of the toweling to be extended from the housing such thatwhereby tearing along the line of perforations leaves a residual extentof the toweling extending outside of the housing after tearing. In someembodiments including this feature, but not all such embodiments, themotor assembly is further configured to cause the residual extent of thetoweling to be retracted into the housing after tearing.

In another feature, the motor assembly is configured to cause thetoweling to be extended a predetermined unit length beyond the point atwhich the sensor detects the leading edge of the toweling. In someembodiments including this feature, but not all such embodiments, themotor assembly is configured to cause the toweling to be furtherextended an extent that is less than the predetermined unit length inresponse to the sensing of a hand proximate the dispenser. In someembodiments including this feature, but not all such embodiments, themotor assembly is configured to cause the toweling to be furtherextended an extent that is less than the predetermined unit length suchthat at least one line of perforations is located outside of thehousing, whereby tearing along the line of perforations leaves aresidual extent of the toweling extending outside of the housing aftertearing. Furthermore, the motor assembly also may be configured to causethe toweling to be further extended another predetermined unit lengthbeyond the point at which the sensor detects the leading edge of thetoweling. The toweling may be further extended another predeterminedunit length in response to the continued sensing of the hand proximatethe dispenser.

The predetermined unit length, by which the toweling is extended,preferably is set in a length learn sequence. This length learn sequencepreferably includes the steps of: (i) retracting the toweling until aleading edge of the toweling is sensed by the sensor; (ii) advancing thetoweling a preset extended length, the preset extended length beinggreater than at least a distance between immediately adjacent lines ofperforations in the toweling; (iii) retracting the toweling until aleading edge of the toweling is sensed by the sensor while measuring alength by which the toweling is retracted; and (iv) determining thedifference between the preset extended length and the measured retractedlength, the difference being the predetermined unit length. The presetextended length may be greater than twice the distance betweenimmediately adjacent lines of perforations in the toweling, whereby thepredetermined unit length may be set for dispensing up to two towels ata time; may be greater than three times the distance between immediatelyadjacent lines of perforations in the toweling, whereby thepredetermined unit length may be set for dispensing up to three towelsat a time; or may be greater than four times the distance betweenimmediately adjacent lines of perforations in the toweling, whereby thepredetermined unit length may be set for dispensing up to four towels ata time. The length learn sequence of the dispenser may be initiated byinstalling a roll of paper towels in the dispenser. This is preferablyaccomplished by moving a loading door of the dispenser, through which aroll of paper towels is received, to a closed position, with a length ofthe toweling preferably being draped over and extending from the loadingdoor.

In still another feature of this aspect, the motor assembly includes amotor and a controller that is configured to control operation of themotor and the subsequent extension of the toweling from and retractionof the toweling into the housing. With regard to this feature, themethod preferably includes the step of: measuring extension of thetoweling from the housing; measuring retraction of the toweling into thehousing; or both. In some embodiments including this feature, but notall such embodiments, such measuring is performed using an encoderpinwheel that rotates during extension and retraction of the toweling.In some embodiments including this feature, but not all suchembodiments, such measuring is performed using an LED component,complementary metal oxide semiconductor (CMOS) component, and digitalsignal processor (DSP) component; or a laser component, complementarymetal oxide semiconductor (CMOS) component, and digital signal processor(DSP) component. Moreover, the sensor for detecting the leading edge ofthe toweling may be comprised of the LED component, complementary metaloxide semiconductor (CMOS) component, and digital signal processor(DSP); or may be comprised of the laser component, complementary metaloxide semiconductor (CMOS) component, and digital signal processor (DSP)component.

In a feature, a loading door of the dispenser comprises a guidingsurface along which toweling rides when retracted into the housing, theguiding surface forming a backdrop that is dark and contrasts well withthe toweling so as to better define the leading edge of the toweling forsensing by the sensor.

In a feature, the loading door further comprises a guiding surface alongwhich toweling rides when being extended from or retracted into thehousing. In some embodiments including this feature, but not all suchembodiments, the guiding surface forms a backdrop to the toweling thatis dark and contrasts well so as to better define the leading edge ofthe toweling for sensing by the sensor.

In another feature of this aspect, the towel dispenser includes a sensorfor detecting movement of the loading door out of the closed position.

In another aspect, a method of dispensing towels from toweling with adispenser includes the steps of extending the toweling exterior of thehousing for grasping by a user; and subsequent thereto, retracting thetoweling into the housing. The housing includes a main body and aloading door that is configured to rotate relative to the main bodybetween a closed position, in which the housing is configured to extendtoweling there from, and an open position, in which the housing isconfigured to receive toweling therein. Furthermore, the loading doorcomprises a towel carrier that has a curved surface defining a cavitywithin which toweling comprising a roll of paper towels is received andretained in floating engagement therewith such that the roll of papertowels rolls and slides on the curved surface when unwinding during saidstep of extending the toweling exterior of the housing for grasping by auser. In some embodiments including this feature, but not all suchembodiments, the toweling gathers within the housing during said step ofretracting the toweling into the housing, and the toweling is not woundback onto the roll of paper towels.

In another feature of this aspect, the housing further comprises a guidesystem that is configured to guide the toweling within the housingduring extension from and retraction into the housing of the toweling.The guide system comprising a first roller attached to the main body andhaving a first toothed surface, and a second roller attached to theloading door and having a second toothed surface that is configured tomesh with the first toothed surface. At least one end of the firstroller moves such that an axis of rotation of the first roller movesrelative to the main body of the housing, and the method furthercomprises the step of moving the loading door into the closed positionafter loading toweling within the dispenser, with the first roller beingurged into engagement with the second roller when the loading doorenters the closed position and the second roller acting on the firstroller so as to displace at least one end of the first roller when theloading door enters the closed position. In some embodiments includingthis feature, but not all such embodiments, the dispenser furthercomprises a motor assembly configured to cause a leading edge of thetoweling to be extended from a housing of the dispenser and to cause thetoweling to be subsequently retracted back into the housing, and both ofthe steps of extending the toweling exterior of the housing for graspingby a user and the step of retracting the toweling into the housing areaccomplished using the motor assembly. The method further comprising thesteps of sensing a leading edge of the toweling while retracting thetoweling into the housing, and ceasing retracting of the toweling intothe housing as a function of sensing the leading edge of the toweling.

In a feature, the housing comprises extension walls located proximateopposite exterior sides of the housing that extend above a top side ofthe housing, and wherein the method further comprises a preliminary stepof mounting the dispenser to the underside of a fixture, includingremoving a portion of each extension wall along a score line so as toadjust the distance from the underside of the fixture below which thetop side of the housing is mounted. In some embodiments including thisfeature, but not all such embodiments, the dispenser further comprises amotor assembly configured to cause a leading edge of the toweling to beextended from a housing of the dispenser and to cause the toweling to besubsequently retracted back into the housing, both of the steps ofextending the toweling exterior of the housing for grasping by a userand the step of retracting the toweling into the housing beingaccomplished using the motor assembly; and the method further comprisingthe steps of sensing a leading edge of the toweling while retracting thetoweling into the housing, and ceasing retracting of the toweling intothe housing as a function of sensing the leading edge of the toweling.

In a feature, the toweling comprises a roll of paper towels and thedispenser is configured to unwind roll of paper towels during extensionof toweling from the housing but not rewind the roll of paper towelsduring subsequent retraction of toweling into the housing, and a backside of the housing includes an opening that is configured such thatexcess toweling gathering within the housing may fall as a result ofretraction of toweling back into the housing. In some embodimentsincluding this feature, but not all such embodiments, the dispenserfurther comprises a motor assembly configured to cause a leading edge ofthe toweling to be extended from a housing of the dispenser and to causethe toweling to be subsequently retracted back into the housing, andboth of the steps of extending the toweling exterior of the housing forgrasping by a user and the step of retracting the toweling into thehousing are accomplished using the motor assembly; and the methodfurther comprising the steps of sensing a leading edge of the towelingwhile retracting the toweling into the housing, and ceasing retractingof the toweling into the housing as a function of sensing the leadingedge of the toweling.

In another aspect, a towel dispenser includes: a housing for receivingtoweling and a guide system that is configured to guide the towelingwithin the housing while towels are dispensed from the housing. Thehousing includes a main body and a loading door that is configured torotate relative to the main body between a closed position, in which thehousing is configured to dispense towels there from, and an openposition, in which the housing is configured to receive towelingtherein. Furthermore, the loading door comprises a towel carrier havinga curved surface defining a cavity configured to receive the roll ofpaper towels in floating engagement therewith such that the roll ofpaper towels rolls and slides on the curved surface during unwinding. Insome embodiments including this feature, but not all such embodiments,the housing further comprises a guide system that is configured to guidethe toweling within the housing during extension from and retractioninto the housing of the toweling. The guide system comprises a firstroller attached to the main body and having a first toothed surface, anda second roller attached to the loading door and having a second toothedsurface that is configured to mesh with the first toothed surface. Atleast one end of the first roller moves such that an axis of rotation ofthe first roller moves relative to the main body of the housing, and thefirst roller is spring biased toward engagement with the second rollerwhen the loading door is in the closed position. Moreover, the toothedsurfaces of the first roller and the second roller mesh together whenthe loading door moves into the closed position from the open positionand do not preclude the loading door from moving into the closedposition from the open position. Also, in some of these embodiments, thehousing further comprises a motor assembly and a sensor. The motorassembly is configured to cause a leading edge of the toweling to beextended from the housing and to cause the toweling to be retracted intothe housing after the leading edge has been extended. The sensor sensesa leading edge of the toweling during retraction of the toweling by themotor assembly, and the sensor is configured to cause the motor assemblyto cease retracting the toweling into the housing as a function of thesensing of the leading edge of the toweling during retraction of thetoweling into the housing.

In another feature of this aspect, the housing further comprisesextension walls located proximate opposite exterior sides of the housingthat extends above a top side of the housing, each extension wallcomprising a weakened line extending parallel to a weakened line of theother extension walls, whereby the extent above the top side at whicheach extension walls extends may be changed, the extent representing adistance from the underside of a fixture below which the top side of thehousing is mounted when the towel dispenser is installed under thefixture. In some embodiments including this feature including thisfeature, but not all such embodiments, the housing further comprises amotor assembly and a sensor. The motor assembly is configured to cause aleading edge of the toweling to be extended from the housing and tocause the toweling to be retracted into the housing after the leadingedge has been extended. The sensor senses a leading edge of the towelingduring retraction of the toweling by the motor assembly, and the sensoris configured to cause the motor assembly to cease retracting thetoweling into the housing as a function of the sensing of the leadingedge of the toweling during retraction of the toweling into the housing.

In another feature, a back side of the housing includes an openingconfigured to permit excess toweling to fall during retraction of thetoweling back into the housing. In some embodiments including thisfeature, but not all such embodiments, the housing further comprises amotor assembly and a sensor. The motor assembly is configured to cause aleading edge of the toweling to be extended from the housing and tocause the toweling to be retracted into the housing after the leadingedge has been extended. The sensor senses a leading edge of the towelingduring retraction of the toweling by the motor assembly, and the sensoris configured to cause the motor assembly to cease retracting thetoweling into the housing as a function of the sensing of the leadingedge of the toweling during retraction of the toweling into the housing.

In still another feature of this aspect, the guide system comprises afirst roller attached to the main body and a second roller attached tothe loading door. In some embodiments including this feature, but notall such embodiments, the second roller is the only roller of the guidesystem affixed to the loading door. In some embodiments including thisfeature, but not all such embodiments, the second roller comprises alower drive roller of the guide system, and the first roller comprisesan upper drive roller of the guide system, the lower drive rollerengaging the upper drive roller with toweling extending there betweenwhen the loading door is moved into the closed position with towelingdraped over the loading door. Also, in some embodiments including thisfeature, but not all such embodiments, the loading door has a secondcurved surface that defines a second cavity within which the secondroller is retained. Additionally, the loading door may include a firstcomponent, a surface of which comprises the curved surface defining thecavity within which the roll of paper towels is received and retained,and a second component, a surface of which comprises the second curvedsurface defining the second cavity within which the second roller isretained, wherein the second component is affixed to the firstcomponent. Furthermore, in this regard, the second component may furtherdefine a guiding surface along which toweling rides when extended fromthe housing.

In another feature of this aspect, the towel dispenser further comprisesa sensor that is mounted to the main body and configured to sense aleading edge of the toweling between a gap formed by the main body andthe loading door when the loading door is in the closed position. Insome embodiments incorporating this feature, but not all suchembodiments, the loading door comprises a guiding surface that providesa backdrop to toweling, the sensor sensing the leading edge of thetoweling against the backdrop of the guiding surface of the loadingdoor. The sensor may comprise a sensor array. Also, In some embodimentsincorporating this feature, but not all such embodiments, the guidesystem comprises a first roller attached to the main body and a secondroller attached to the loading door. The second roller may be the onlyroller of the guide system on the loading door; the loading door mayhave a second curved surface defining a second cavity within which thesecond roller is received and retained; and the loading door maycomprise a first component, a surface of which comprises the curvedsurface defining the cavity within which the roll of paper towels isreceived and retained, and a second component affixed to the firstcomponent, a surface of the second component comprising the secondcurved surface defining the second cavity within which the second rolleris received and retained. The second component also further may define aguiding surface against which toweling rides when extended from thehousing.

In another aspect of the invention, a method of dispensing towels fromtoweling with a dispenser includes the steps of extending the towelingexterior of the housing for grasping by a user; and subsequent thereto,retracting the toweling into the housing. In this regard, the housingcomprises a main body, a loading door, and a guide system. The loadingdoor is configured to rotate relative to the main body between closedposition, in which the housing is configured to extend toweling therefrom, and an open position, in which the housing is configured toreceive toweling therein. The guide system is configured to guide thetoweling within the housing during extension from and retraction intothe housing of the toweling, and comprises a first roller attached tothe main body and having a first toothed surface, and a second rollerattached to the loading door and having a second toothed surface that isconfigured to mesh with the first toothed surface. At least one end ofthe first roller moves such that an axis of rotation of the first rollermoves relative to the main body of the housing. The method furtherincludes the step of moving the loading door into the closed positionafter loading toweling within the dispenser, with the first roller beingurged into engagement with the second roller when the loading doorenters the closed position and the second roller acting on the firstroller so as to displace at least one end of the first roller when theloading door enters the closed position.

In a feature of this aspect, the housing comprises extension wallslocated proximate opposite exterior sides of the housing that extendabove a top side of the housing, and the method further comprises apreliminary step of mounting the dispenser to the underside of afixture, including removing a portion of each extension wall along ascore line so as to adjust the distance from the underside of thefixture below which the top side of the housing is mounted. In someembodiments incorporating this feature, but not all such embodiments,the dispenser further comprises a motor assembly configured to cause aleading edge of the toweling to be extended from a housing of thedispenser and to cause the toweling to be subsequently retracted backinto the housing, both of the steps of extending the toweling exteriorof the housing for grasping by a user and the step of retracting thetoweling into the housing being accomplished using the motor assembly;and the method further comprises the steps of sensing a leading edge ofthe toweling while retracting the toweling into the housing, and ceasingretracting of the toweling into the housing as a function of sensing theleading edge of the toweling. Also, In some embodiments incorporatingthis feature, but not all such embodiments, the loading door comprises atowel carrier having a curved surface defining a cavity within whichtoweling comprising a roll of paper towels is received and retained infloating engagement therewith, the roll of paper towels rolling andsliding on the curved surface when unwinding during said step ofextending the toweling exterior of the housing for grasping by a user,and toweling gathering within the housing during retracting of thetoweling into the housing and not being wound back onto the roll ofpaper towels.

In a feature of this aspect, the toweling comprises a roll of papertowels and the dispenser is configured to unwind roll of paper towelsduring extension of toweling from the housing but not rewind the roll ofpaper towels during subsequent retraction of toweling into the housing.Furthermore, a back side of the housing includes an opening that isconfigured such that excess toweling gathering within the housing mayfall there through as a result of retraction of toweling back into thehousing. In some embodiments incorporating this feature, but not allsuch embodiments, the dispenser further comprises a motor assemblyconfigured to cause a leading edge of the toweling to be extended from ahousing of the dispenser and to cause the toweling to be subsequentlyretracted back into the housing, both of the steps of extending thetoweling exterior of the housing for grasping by a user and the step ofretracting the toweling into the housing being accomplished using themotor assembly; and the method further comprises the steps of sensing aleading edge of the toweling while retracting the toweling into thehousing, and ceasing retracting of the toweling into the housing as afunction of sensing the leading edge of the toweling. Also, In someembodiments incorporating this feature, but not all such embodiments,the loading door comprises a towel carrier having a curved surfacedefining a cavity within which toweling comprising a roll of papertowels is received and retained in floating engagement therewith, theroll of paper towels rolling and sliding on the curved surface whenunwinding during said step of extending the toweling exterior of thehousing for grasping by a user, and toweling gathering within thehousing during retracting of the toweling into the housing and not beingwound back onto the roll of paper towels.

In another aspect, a towel dispenser comprises a housing for receivingtoweling. The housing includes a main body, a loading door, and a guidesystem. The loading door is configured to rotate relative to the mainbody between a closed position, in which the housing is configured todispense towels there from, and an open position, in which the housingis configured to receive toweling therein. The guide system isconfigured to guide the toweling within the housing while towels aredispensed from the housing. Furthermore, the guide system comprises afirst roller attached to the main body and having a first toothedsurface, and a second roller attached to the loading door and having asecond toothed surface that is configured to mesh with the first toothedsurface. The toothed surfaces of the first roller and the second rollermesh together when the loading door moves into the closed position fromthe open position and do not preclude the loading door from moving intothe closed position from the open position. In a feature of this aspect,the housing further comprises extension walls located proximate oppositeexterior sides of the housing that extends above a top side of thehousing, each extension wall comprising a weakened line extendingparallel to a weakened line of the other extension walls, whereby theextent above the top side at which each extension walls extends may bechanged, the extent representing a distance from the underside of afixture below which the top side of the housing is mounted when thetowel dispenser is installed under the fixture. In some embodimentsincorporating this feature, but not all such embodiments, the housingfurther comprises a motor assembly configured to cause a leading edge ofthe toweling to be extended from the housing and to cause the towelingto be retracted into the housing after the leading edge has beenextended, and a sensor for sensing a leading edge of the toweling duringretraction of the toweling by the motor assembly. The sensor isconfigured to cause the motor assembly to cease retracting the towelinginto the housing as a function of the sensing of the leading edge of thetoweling during retraction of the toweling into the housing. Also, Insome embodiments incorporating this feature, but not all suchembodiments, the loading door comprises a towel carrier having a curvedsurface defining a cavity configured to receive the roll of paper towelsin floating engagement therewith such that the roll of paper towelsrolls and slides on the curved surface during unwinding.

In another feature of this aspect, a back side of the housing includesan opening configured to permit excess toweling to fall duringretraction of the toweling back into the housing. In some embodimentsincorporating this feature, but not all such embodiments, the housingfurther comprises a motor assembly configured to cause a leading edge ofthe toweling to be extended from the housing and to cause the towelingto be retracted into the housing after the leading edge has beenextended, and a sensor for sensing a leading edge of the toweling duringretraction of the toweling by the motor assembly, wherein the sensor isconfigured to cause the motor assembly to cease retracting the towelinginto the housing as a function of the sensing of the leading edge of thetoweling during retraction of the toweling into the housing. In someembodiments incorporating this feature, but not all such embodiments,the loading door comprises a towel carrier having a curved surfacedefining a cavity configured to receive the roll of paper towels infloating engagement therewith such that the roll of paper towels rollsand slides on the curved surface during unwinding.

In a feature of this aspect, each toothed surfaces has a fairly largeand forgiving tooth geometry.

In another feature, the first roller engages the second roller when theloading door is in the closed position.

In a feature, an axis of rotation of the first roller is located aboveand forward of an axis of rotation of the second roller when the loadingdoor is in the closed position.

In a feature, the first roller extends generally alongside a compartmentof the housing in which a battery is received, the compartment beingaccessible through a removable front cover of the housing for changingthe battery.

In a feature, each toothed surface comprises an axially mounted endgear.

In a feature, the first toothed surfaces is located proximate a firstend of the first roller, and wherein the second toothed surface islocated proximate a first end of the second roller, the respective firstends of the first and second rollers being located proximate one anotherwhen the loading door is in the closed position.

In a feature, a transmission connects a motor to a second end of thefirst roller, the second end of the first roller being opposite to thefirst end of the first roller. In some various embodiments incorporatingthis feature, but not all such embodiments, the first end of the firstroller is configured to move vertically a small extent, but the secondend of the first roller is not configured to move vertically a smallextent; the toothed surface of the first roller is spring biased intomeshing engagement with the toothed surface of the second roller whenthe loading door moves into the closed position from the open position;and the second end of the first roller comprises a pivot point of thefirst roller. Also, in some embodiments incorporating this feature, butnot all such embodiments, the first end of the first roller floatsrelative to the main body, but the second end of the first roller isfixed relative to the main body. In this respect, the toothed surface ofthe first roller may be spring biased into meshing engagement with thetoothed surface of the second roller when the loading door moves intothe closed position from the open position, and the second end of thefirst roller may comprise a pivot point of the first roller.

In a feature, a belt engages the second end of the first roller fordriving of the first roller by the motor.

In a feature, the toothed surface of the first roller is spring biasedinto meshing engagement with the toothed surface of the second rollerwhen the loading door moves into the closed position from the openposition.

In still another feature, the only rollers of the guide system are thefirst and second rollers.

In another aspect of the invention, a towel dispenser comprises ahousing for receiving toweling. The housing comprises a main body, aloading door, and a guide system. The loading door is configured torotate relative to the main body between a closed position, in which thehousing is configured to dispense towels there from, and an openposition, in which the housing is configured to receive towelingtherein. The guide system is configured to guide the toweling within thehousing while towels are dispensed from the housing and comprises afirst roller attached to the main body and having a toothed surfaceproximate a first end thereof, and a second roller attached to theloading door and having a toothed surface proximate a first end thereofthat is configured to mesh with the toothed surface of the first roller.The housing further comprises a transmission that connects a motor to asecond end of the first roller, the second end of the first roller beingopposite the first end of the first roller.

In a feature of this aspect, the motor is located within the main bodybetween the first roller and a front panel of the housing.

In a feature of this aspect, the housing further comprises a batterycompartment and wherein the motor is battery powered, the batterycompartment and motor being located within the main body between thefirst roller and a front panel of the housing.

In a feature of this aspect, the first end of the first roller isconfigured to move vertically by a small extent, but the second end ofthe first roller is not configured to move vertically by a small extent.In various embodiments incorporating this feature, but not all suchembodiments, the toothed surface of the first roller is spring biasedinto meshing engagement with the toothed surface of the second rollerwhen the loading door is in the closed position; and the second end ofthe first roller comprises a pivot point of the first roller.

In a feature of this aspect, the first end of the first roller floatsrelative to the main body, but the second end of the first roller isfixed relative to the main body.

In a feature of this aspect, the toothed surface of the first roller isspring biased into meshing engagement with the toothed surface of thesecond roller when the loading door moves into the closed position fromthe open position. In various embodiments incorporating this feature,but not all such embodiments, the second end of the first rollercomprises a pivot point of the first roller.

In a feature of this aspect, a belt engages the first roller proximate asecond end thereof for driving of the first roller by the motor.

In a feature of this aspect, the toothed surface of the first roller isspring biased into meshing engagement with the toothed surface of thesecond roller when the loading door is in the closed position.

In a feature of this aspect, the only rollers of the guide system arethe first and second rollers.

In still another aspect, a towel dispenser includes a housing forreceiving toweling. The housing comprises a main body, a loading door,and a guide system. The loading door that is configured to rotaterelative to the main body between a closed position, in which thehousing is configured to dispense towels there from, and an openposition, in which the housing is configured to receive towelingtherein. The guide system is configured to guide the toweling within thehousing while towels are dispensed from the housing, and includes afirst roller attached to the main body and having a first toothedsurface, and a second roller attached to the loading door and having asecond toothed surface that is configured to mesh with the first toothedsurface. The first roller is spring biased toward engagement with thesecond roller when the loading door is in the closed position.

In a feature of this aspect, a transmission connects a motor to a secondend of the first roller, the second end of the first roller beingopposite to the first end of the first roller. In some embodimentsincorporating this feature, but not all such embodiments, the first endof the first roller is configured to move vertically a small extent, butthe second end of the first roller is not configured to move verticallya small extent. Additionally, in various ones of such embodiments, thesecond end of the first roller comprises a pivot point of the firstroller; the first end of the first roller floats relative to the mainbody, but the second end of the first roller is fixed relative to themain body; and the second end of the first roller comprises a pivotpoint of the first roller.

In a feature of this aspect, a belt engages the second end of the firstroller for driving of the first roller by the motor.

In another feature of this aspect, the only rollers of the guide systemare the first and second rollers.

In yet another feature of this aspect, the second roller acts againstthe spring biasing of the first roller to displace at least one end ofthe first roller when the loading door is moved into the closedposition.

In an aspect of the invention, a method of dispensing towels fromtoweling with a dispenser includes the steps of: extending the towelingexterior of a housing of the dispenser for grasping by a user; andsubsequent thereto, retracting the toweling into the housing. Thehousing comprises extension walls located proximate opposite exteriorsides of the housing that extend above a top side of the housing, andthe method further comprises a preliminary step of mounting thedispenser to the underside of a fixture, including removing a portion ofeach extension wall along a score line so as to adjust the distance fromthe underside of the fixture below which the top side of the housing ismounted.

In a feature of this aspect, the toweling comprises a roll of papertowels and the dispenser is configured to unwind roll of paper towelsduring extension of toweling from the housing but not rewind the roll ofpaper towels during subsequent retraction of toweling into the housing,and a back side of the housing includes an opening that is configuredsuch that excess toweling gathering within the housing may fall as aresult of retraction of toweling back into the housing. In embodimentsthat incorporate this feature, but not all such embodiments, the methodfurther comprises the steps of: using a motor assembly configured tocause a leading edge of the toweling to be extended from a housing ofthe dispenser and to cause the toweling to be subsequently retractedback into the housing in said steps of the method; sensing a leadingedge of the toweling while retracting the toweling; and ceasingretracting of the toweling into the housing using the motor assembly asa function of sensing the leading edge of the toweling by the sensor.Also, in embodiments that incorporate this feature, but not all suchembodiments, the housing comprises a main body, and a loading door thatis configured to rotate relative to the main body between a closedposition, in which the housing is configured to extend toweling therefrom, and an open position, in which the housing is configured toreceive toweling therein. Furthermore, the loading door comprises atowel carrier having a curved surface defining a cavity within whichtoweling comprising a roll of paper towels is received and retained infloating engagement therewith such that the roll of paper towels rollsand slides on the curved surface when unwinding during said step ofextending the toweling exterior of the housing for grasping by a user.The toweling further gathers within the housing during retracting of thetoweling into the housing and is not wound back onto the roll of papertowels. Still yet in embodiments that incorporate this feature, but notall such embodiments, the housing comprises a main body, a loading doorthat is configured to rotate relative to the main body between a closedposition, in which the housing is configured to extend toweling therefrom, and an open position, in which the housing is configured toreceive toweling therein, and a guide system that is configured to guidethe toweling within the housing during extension from and retractioninto the housing of the toweling, the guide system comprising a firstroller attached to the main body and having a first toothed surface, anda second roller attached to the loading door and having a second toothedsurface that is configured to mesh with the first toothed surface. Inthis respect, at least one end of the first roller moves such that anaxis of rotation of the first roller moves relative to the main body ofthe housing, and the method further comprises the step of moving theloading door into the closed position after loading toweling within thedispenser, with the first roller being urged into engagement with thesecond roller when the loading door enters the closed position and thesecond roller acting on the first roller so as to displace at least oneend of the first roller when the loading door enters the closedposition.

In another feature, each extension wall is integral with the main bodyof the housing.

In a feature, each extension wall is integrally formed with the mainbody of the housing.

In a feature, each extension wall extends opposite side walls of thehousing beyond the top side of the housing.

In a feature, each extension wall is configured to be broken off by handupon bending along a weakened line of the extension wall.

In a feature, each extension wall includes a plurality of weakenedlines.

In a feature, weakened line of an extension wall extends in parallel to,and at the same height from the top side of the housing, as acorresponding weakened line of the other extension wall.

In another aspect of the invention, a towel dispenser comprises ahousing for receiving toweling comprising a roll of paper towels, thehousing in turn comprising extension walls located proximate oppositeexterior sides of the housing that extends above a top side of thehousing, each extension wall comprising a weakened line extendingparallel to a weakened line of the other extension walls, whereby theextent above the top side at which each extension walls extends may bechanged, the extent representing a distance from the underside of afixture below which the top side of the housing is mounted when thetowel dispenser is installed under the fixture.

In a feature of this aspect, a back side of the housing includes anopening configured to permit excess toweling to fall there throughduring retraction of the toweling into the housing. In some embodimentsincorporating this feature, but not all such embodiments, the housingfurther comprises a motor assembly configured to cause a leading edge ofthe toweling to be extended from the housing and to cause the towelingto be retracted into the housing after the leading edge has beenextended; and a sensor for sensing a leading edge of the toweling duringretraction of the toweling by the motor assembly. The sensor isconfigured to cause the motor assembly to cease retracting the towelinginto the housing as a function of the sensing of the leading edge of thetoweling during retraction of the toweling into the housing. Also, insome embodiments incorporating this feature, but not all suchembodiments, the housing comprises a main body and a loading door thatis configured to rotate relative to the main body between a closedposition, in which the housing is configured to extend toweling therefrom, and an open position, in which the housing is configured toreceive toweling therein. The loading door comprises a towel carrierhaving a curved surface defining a cavity configured to receive the rollof paper towels in floating engagement therewith such that the roll ofpaper towels rolls and slides on the curved surface during unwinding.

In another feature of this aspect, the towel dispenser includes ahousing that, in turn, comprises a main body, a loading door, and aguide system. The loading door is configured to rotate relative to themain body between a closed position, in which the housing is configuredto extend toweling there from, and an open position, in which thehousing is configured to receive toweling therein. The guide system isconfigured to guide the toweling within the housing during extensionfrom and retraction into the housing of the toweling, the guide systemcomprising a first roller attached to the main body and having a firsttoothed surface, and a second roller attached to the loading door andhaving a second toothed surface that is configured to mesh with thefirst toothed surface. At least one end of the first roller moves suchthat an axis of rotation of the first roller moves relative to the mainbody of the housing, the first roller is spring biased toward engagementwith the second roller when the loading door is in the closed position,and the toothed surfaces of the first roller and the second roller meshtogether when the loading door moves into the closed position from theopen position and do not preclude the loading door from moving into theclosed position from the open position.

In another aspect, a method of dispensing towels from toweling with adispenser includes the steps of: extending the toweling exterior of ahousing of the dispenser for grasping by a user; and subsequent thereto,retracting the toweling into the housing. The toweling comprises a rollof paper towels and the dispenser is configured to unwind roll of papertowels during extension of toweling from the housing but not rewind theroll of paper towels during subsequent retraction of toweling into thehousing, and a back side of the housing includes an opening that isconfigured such that excess toweling gathering within the housing mayfall as a result of retraction of toweling back into the housing.

In a feature of this aspect, the method further includes the steps of:using a motor assembly configured to cause a leading edge of thetoweling to be extended from a housing of the dispenser and to cause thetoweling to be subsequently retracted back into the housing, performingsaid steps of extending the toweling exterior of the housing forgrasping by a user and subsequent thereto, retracting the toweling intothe housing; and, using a sensor for sensing a leading edge of thetoweling, sensing a leading edge of the toweling while retracting thetoweling; ceasing retracting of the toweling into the housing using themotor assembly as a function of sensing the leading edge of the towelingby the sensor. Further in this respect, the housing comprises a mainbody, a loading door, and a guide system. The loading door is configuredto rotate relative to the main body between a closed position, in whichthe housing is configured to extend toweling there from, and an openposition, in which the housing is configured to receive towelingtherein. The guide system is configured to guide the toweling within thehousing during extension from and retraction into the housing of thetoweling, the guide system comprising a first roller attached to themain body and having a first toothed surface, and a second rollerattached to the loading door and having a second toothed surface that isconfigured to mesh with the first toothed surface, at least one end ofthe first roller being configured to move such that an axis of rotationof the first roller moves relative to the main body of the housing. Theloading door further comprises a towel carrier having a curved surfacedefining a cavity within which toweling comprising a roll of papertowels is received and retained in floating engagement therewith, theroll of paper towels rolling and sliding on the curved surface whenunwinding during said step of extending the toweling exterior of thehousing for grasping by a user, and toweling gathering within thehousing during retracting of the toweling into the housing and not beingwound back onto the roll of paper towels. Additionally, the methodfurther comprises the step of moving the loading door into the closedposition after loading toweling within the dispenser, with the firstroller being urged into engagement with the second roller when theloading door enters the closed position and the second roller acting onthe first roller so as to displace at least one end of the first rollerwhen the loading door enters the closed position.

In a feature of this aspect, the method further comprises the steps of:using a motor assembly configured to cause a leading edge of thetoweling to be extended from a housing of the dispenser and to cause thetoweling to be subsequently retracted back into the housing, performingsaid steps of extending the toweling exterior of the housing forgrasping by a user and subsequent thereto, retracting the toweling intothe housing; using a sensor for sensing a leading edge of the toweling,sensing a leading edge of the toweling while retracting the toweling;and ceasing retracting of the toweling into the housing using the motorassembly as a function of sensing the leading edge of the toweling bythe sensor. Further in this respect, the housing comprises a main body,a loading door, and a guide system. The loading door is configured torotate relative to the main body between a closed position, in which thehousing is configured to extend toweling there from, and an openposition, in which the housing is configured to receive towelingtherein. The loading door further comprises a towel carrier having acurved surface defining a cavity within which toweling comprising a rollof paper towels is received and retained in floating engagementtherewith, the roll of paper towels rolling and sliding on the curvedsurface when unwinding during said step of extending the towelingexterior of the housing for grasping by a user, and toweling gatheringwithin the housing during retracting of the toweling into the housingand not being wound back onto the roll of paper towels. The housingcomprises extension walls located proximate opposite exterior sides ofthe housing that extend above a top side of the housing, and wherein themethod further comprises a preliminary step of mounting the dispenser tothe underside of a fixture, including removing a portion of eachextension wall along a score line so as to adjust the distance from theunderside of the fixture below which the top side of the housing ismounted.

In a feature of this aspect, the housing comprises a main body and aloading door that is configured to rotate relative to the main bodybetween a closed position, in which the housing is configured to extendtoweling there from, and an open position, in which the housing isconfigured to receive toweling therein. The housing also comprise aguide system that is configured to guide the toweling within the housingduring extension from and retraction into the housing of the toweling,the guide system comprising a first roller attached to the main body andhaving a first toothed surface, and a second roller attached to theloading door and having a second toothed surface that is configured tomesh with the first toothed surface, at least one end of the firstroller being configured to move such that an axis of rotation of thefirst roller moves relative to the main body of the housing. Further inthis respect, the loading door comprises a towel carrier having a curvedsurface defining a cavity within which toweling comprising a roll ofpaper towels is received and retained in floating engagement therewith,the roll of paper towels rolling and sliding on the curved surface whenunwinding during said step of extending the toweling exterior of thehousing for grasping by a user, and toweling gathering within thehousing during retracting of the toweling into the housing and not beingwound back onto the roll of paper towels; the method further comprisesthe step of moving the loading door into the closed position afterloading toweling within the dispenser, with the first roller being urgedinto engagement with the second roller when the loading door enters theclosed position and the second roller acting on the first roller so asto displace at least one end of the first roller when the loading doorenters the closed position; and wherein the housing comprises extensionwalls located proximate opposite exterior sides of the housing thatextend above a top side of the housing, and wherein the method furthercomprises a preliminary step of mounting the dispenser to the undersideof a fixture, including removing a portion of each extension wall alonga score line so as to adjust the distance from the underside of thefixture below which the top side of the housing is mounted.

In a feature of this aspect, the method further comprises the steps of:using a motor assembly configured to cause a leading edge of thetoweling to be extended from a housing of the dispenser and to cause thetoweling to be subsequently retracted back into the housing, performingsaid steps of extending the toweling exterior of the housing forgrasping by a user and subsequent thereto, retracting the toweling intothe housing; using a sensor for sensing a leading edge of the toweling,sensing a leading edge of the toweling while retracting the toweling;and ceasing retracting of the toweling into the housing using the motorassembly as a function of sensing the leading edge of the toweling bythe sensor. The housing comprises a main body, a loading door, and aguide system. The loading door is configured to rotate relative to themain body between a closed position, in which the housing is configuredto extend toweling there from, and an open position, in which thehousing is configured to receive toweling therein. The guide system isconfigured to guide the toweling within the housing during extensionfrom and retraction into the housing of the toweling, the guide systemcomprising a first roller attached to the main body and having a firsttoothed surface, and a second roller attached to the loading door andhaving a second toothed surface that is configured to mesh with thefirst toothed surface, at least one end of the first roller beingconfigured to move such that an axis of rotation of the first rollermoves relative to the main body of the housing. Further in this respect,the method further comprises the step of moving the loading door intothe closed position after loading toweling within the dispenser, withthe first roller being urged into engagement with the second roller whenthe loading door enters the closed position and the second roller actingon the first roller so as to displace at least one end of the firstroller when the loading door enters the closed position; and the housingcomprises extension walls located proximate opposite exterior sides ofthe housing that extend above a top side of the housing, and wherein themethod further comprises a preliminary step of mounting the dispenser tothe underside of a fixture, including removing a portion of eachextension wall along a score line so as to adjust the distance from theunderside of the fixture below which the top side of the housing ismounted.

In yet another feature of this aspect, the method further comprises thesteps of: using a motor assembly configured to cause a leading edge ofthe toweling to be extended from a housing of the dispenser and to causethe toweling to be subsequently retracted back into the housing,performing said steps of extending the toweling exterior of the housingfor grasping by a user and subsequent thereto, retracting the towelinginto the housing; using a sensor for sensing a leading edge of thetoweling, sensing a leading edge of the toweling while retracting thetoweling; and ceasing retracting of the toweling into the housing usingthe motor assembly as a function of sensing the leading edge of thetoweling by the sensor. Further in this respect, the housing comprises amain body, a loading door, and a guide system. The loading door isconfigured to rotate relative to the main body between a closedposition, in which the housing is configured to extend toweling therefrom, and an open position, in which the housing is configured toreceive toweling therein. The guide system is configured to guide thetoweling within the housing during extension from and retraction intothe housing of the toweling, the guide system comprising a first rollerattached to the main body and having a first toothed surface, and asecond roller attached to the loading door and having a second toothedsurface that is configured to mesh with the first toothed surface, atleast one end of the first roller being configured to move such that anaxis of rotation of the first roller moves relative to the main body ofthe housing. The loading door comprises a towel carrier having a curvedsurface defining a cavity within which toweling comprising a roll ofpaper towels is received and retained in floating engagement therewith,the roll of paper towels rolling and sliding on the curved surface whenunwinding during said step of extending the toweling exterior of thehousing for grasping by a user, and toweling gathering within thehousing during retracting of the toweling into the housing and not beingwound back onto the roll of paper towels. Furthermore, the methodadditionally comprises the step of moving the loading door into theclosed position after loading toweling within the dispenser, with thefirst roller being urged into engagement with the second roller when theloading door enters the closed position and the second roller acting onthe first roller so as to displace at least one end of the first rollerwhen the loading door enters the closed position. The housing alsofurther comprises extension walls located proximate opposite exteriorsides of the housing that extend above a top side of the housing, andwherein the method further comprises a preliminary step of mounting thedispenser to the underside of a fixture, including removing a portion ofeach extension wall along a score line so as to adjust the distance fromthe underside of the fixture below which the top side of the housing ismounted.

In still yet another aspect of the invention, a towel dispensercomprises a housing for receiving toweling. The housing in turncomprises a main body, a loading door, a guide system, and a motorassembly. The loading door is configured to rotate relative to the mainbody between a closed position, in which the housing is configured todispense towels there from, and an open position, in which the housingis configured to receive toweling therein. The guide system isconfigured to guide the toweling within the housing while towels aredispensed from the housing. The motor assembly is configured to cause aleading edge of the toweling to be extended from the housing and tocause the toweling to be retracted into the housing after the leadingedge has been extended. Furthermore, a back side of the housing includesan opening configured to permit excess toweling to fall there throughduring retraction of the toweling back into the housing by the motorassembly.

In a feature of this aspect, the towel dispenser further comprises asensor for sensing a leading edge of the toweling during retraction ofthe toweling by the motor assembly. The sensor is configured to causethe motor assembly to cease retracting the toweling into the housing asa function of the sensing of the leading edge of the toweling duringretraction of the toweling into the housing. Additionally, the guidesystem comprises a first roller attached to the main body and having afirst toothed surface, and a second roller attached to the loading doorand having a second toothed surface that is configured to mesh with thefirst toothed surface; the loading door comprises a towel carrier havinga curved surface defining a cavity configured to receive the roll ofpaper towels in floating engagement therewith such that the roll ofpaper towels rolls and slides on the curved surface during unwinding; atleast one end of the first roller moves such that an axis of rotation ofthe first roller moves relative to the main body of the housing; thefirst roller is spring biased toward engagement with the second rollerwhen the loading door is in the closed position; and the toothedsurfaces of the first roller and the second roller mesh together whenthe loading door moves into the closed position from the open positionand do not preclude the loading door from moving into the closedposition from the open position.

In a feature of this aspect, the towel dispenser further comprises asensor for sensing a leading edge of the toweling during retraction ofthe toweling by the motor assembly. The sensor is configured to causethe motor assembly to cease retracting the toweling into the housing asa function of the sensing of the leading edge of the toweling duringretraction of the toweling into the housing. Moreover, the loading doorcomprises a towel carrier having a curved surface defining a cavityconfigured to receive the roll of paper towels in floating engagementtherewith such that the roll of paper towels rolls and slides on thecurved surface during unwinding; and the housing further comprisesextension walls located proximate opposite exterior sides of the housingthat extends above a top side of the housing, each extension wallcomprising a weakened line extending parallel to a weakened line of theother extension walls, whereby the extent above the top side at whicheach extension walls extends may be changed, the extent representing adistance from the underside of a fixture below which the top side of thehousing is mounted when the towel dispenser is installed under thefixture.

In still another feature of this aspect, the guide system comprises afirst roller attached to the main body and having a first toothedsurface, and a second roller attached to the loading door and having asecond toothed surface that is configured to mesh with the first toothedsurface; the loading door comprises a towel carrier having a curvedsurface defining a cavity configured to receive the roll of paper towelsin floating engagement therewith such that the roll of paper towelsrolls and slides on the curved surface during unwinding; at least oneend of the first roller moves such that an axis of rotation of the firstroller moves relative to the main body of the housing; the first rolleris spring biased toward engagement with the second roller when theloading door is in the closed position; the toothed surfaces of thefirst roller and the second roller mesh together when the loading doormoves into the closed position from the open position and do notpreclude the loading door from moving into the closed position from theopen position; and the housing further comprises extension walls locatedproximate opposite exterior sides of the housing that extends above atop side of the housing, each extension wall comprising a weakened lineextending parallel to a weakened line of the other extension walls,whereby the extent above the top side at which each extension wallsextends may be changed, the extent representing a distance from theunderside of a fixture below which the top side of the housing ismounted when the towel dispenser is installed under the fixture.

In a feature of this aspect, the towel dispenser further comprises asensor for sensing a leading edge of the toweling during retraction ofthe toweling by the motor assembly. The sensor is configured to causethe motor assembly to cease retracting the toweling into the housing asa function of the sensing of the leading edge of the toweling duringretraction of the toweling into the housing. Moreover, the guide systemcomprises a first roller attached to the main body and having a firsttoothed surface, and a second roller attached to the loading door andhaving a second toothed surface that is configured to mesh with thefirst toothed surface; at least one end of the first roller moves suchthat an axis of rotation of the first roller moves relative to the mainbody of the housing; the first roller is spring biased toward engagementwith the second roller when the loading door is in the closed position;and the toothed surfaces of the first roller and the second roller meshtogether when the loading door moves into the closed position from theopen position and do not preclude the loading door from moving into theclosed position from the open position. Furthermore, the housing furthercomprises extension walls located proximate opposite exterior sides ofthe housing that extends above a top side of the housing, each extensionwall comprising a weakened line extending parallel to a weakened line ofthe other extension walls, whereby the extent above the top side atwhich each extension walls extends may be changed, the extentrepresenting a distance from the underside of a fixture below which thetop side of the housing is mounted when the towel dispenser is installedunder the fixture.

In a feature of this aspect, the towel dispenser further comprises asensor for sensing a leading edge of the toweling during retraction ofthe toweling by the motor assembly. The sensor is configured to causethe motor assembly to cease retracting the toweling into the housing asa function of the sensing of the leading edge of the toweling duringretraction of the toweling into the housing. Moreover, the guide systemcomprises a first roller attached to the main body and having a firsttoothed surface, and a second roller attached to the loading door andhaving a second toothed surface that is configured to mesh with thefirst toothed surface; the loading door comprises a towel carrier havinga curved surface defining a cavity configured to receive the roll ofpaper towels in floating engagement therewith such that the roll ofpaper towels rolls and slides on the curved surface during unwinding; atleast one end of the first roller moves such that an axis of rotation ofthe first roller moves relative to the main body of the housing; thefirst roller is spring biased toward engagement with the second rollerwhen the loading door is in the closed position; the toothed surfaces ofthe first roller and the second roller mesh together when the loadingdoor moves into the closed position from the open position and do notpreclude the loading door from moving into the closed position from theopen position; and the housing further comprises extension walls locatedproximate opposite exterior sides of the housing that extends above atop side of the housing, each extension wall comprising a weakened lineextending parallel to a weakened line of the other extension walls,whereby the extent above the top side at which each extension wallsextends may be changed, the extent representing a distance from theunderside of a fixture below which the top side of the housing ismounted when the towel dispenser is installed under the fixture.

In another aspect of the invention, a towel dispenser comprises: ahousing for receiving toweling, wherein the toweling includes towelsthat are connected together and separable at perforation formed betweenthe towels; a motor configured to selectively cause a leading edge ofthe toweling to be extended from the housing and to cause the towelingto be retracted into the housing; and a sensor for sensing a leadingedge of the toweling. The sensor is configured to cause the motor tocease retracting toweling into the housing in response to the sensing ofthe leading edge of the toweling.

In still yet another aspect of the invention, a method of dispensingtowels from a dispenser includes the steps of: providing (i) a toweldispenser including a housing for containing toweling, wherein thetoweling includes towels connected together and separable atperforations formed there between, (ii) a motor configured toselectively cause a leading edge of the toweling to be extended from thehousing and to cause the toweling to be retracted into the housing, and(iii) a sensor for sensing a leading edge of the toweling; using themotor, extending the toweling exterior of the housing for grasping by auser; using the motor, retracting the toweling into the housing; whileretracting the toweling, sensing a leading edge of the toweling usingthe sensor; and ceasing to retract the toweling into the housing usingthe motor upon sensing the leading edge of the toweling by the sensor.Other aspects of the invention relate to structure of towel dispensersas disclosed herein.

In another aspect of the invention, a method includes advancing towelingusing a motor of a paper towel dispenser apparatus; determining, via asensor, when a certain extent of toweling has been advanced; based onsaid determining when a certain extent of toweling has been advanced,ceasing the advance of the advancing toweling, wherein, upon ceasing theadvance of the advancing toweling, a first length of toweling isextended outside of a housing of the paper towel dispenser apparatus;determining, via the sensor, that the length of toweling extendedoutside of the housing has increased, wherein a second length oftoweling is extended outside of the housing of the paper towel dispenserapparatus, the second length being greater than the first length; and inresponse to said determining that the length of toweling extendedoutside of the housing has increased, applying force to the toweling,via the motor, in a manner adapted to retract the toweling such that thelength of toweling extended outside of the housing decreases.

In a feature of this aspect, said step of applying force to thetoweling, via the motor, in a manner adapted to retract the towelingsuch that the length of toweling extended outside of the housingdecreases comprises applying force to the toweling, via the motor, in amanner adapted to retract the toweling such that the length of towelingextended outside of the housing is once again the first length.

In a feature of this aspect, said step of advancing toweling comprisesproviding current of a first polarity to the motor; said step of ceasingthe advance of the advancing toweling comprises drawing current out ofthe motor; and said step of applying force to the toweling, via themotor, comprises providing current of a second polarity to the motor,the second polarity being reverse of the first polarity.

In a feature of this aspect, the sensor comprises a slot sensor.

In another aspect of the invention, a method includes, when a length oftoweling is extended outside of a housing of a paper towel dispenser,determining, via a sensor, that the length of toweling extended outsideof the housing of the paper towel dispenser has increased; and inresponse to said determining that the length of toweling extendedoutside of the housing has increased, applying force to the toweling,via the motor, in a manner adapted to retract the toweling such that thelength of toweling extended outside of the housing decreases.

In a feature of this aspect, said step of applying force to thetoweling, via the motor, in a manner adapted to retract the towelingsuch that the length of toweling extended outside of the housingdecreases comprises applying force to the toweling, via the motor, in amanner adapted to retract the toweling such that the length of towelingextended outside of the housing is once again the first length.

In a feature of this aspect, the sensor comprises a slot sensor.

In another aspect of the invention, a method includes advancing towelingusing a motor of a paper towel dispenser apparatus; monitoring, via asensor, rotation that occurs as toweling is advanced or retracted;determining, via the sensor, that a certain amount of rotation hasoccurred; based on said determining that a certain amount of rotationhas occurred, ceasing the advance of the advancing toweling; after saidceasing of the advance of the advancing toweling, determining, via thesensor, that additional rotation has occurred; and in response to saiddetermining that a certain amount of rotation has occurred, applyingforce, via the motor, in a manner adapted to counteract the additionalrotation.

In a feature of this aspect, said step of applying force, via the motor,in a manner adapted to counteract the additional rotation compriseseffecting rotation in a direction opposite the direction of theadditional rotation.

In a feature of this aspect, said step of advancing toweling comprisesproviding current of a first polarity to the motor; said step of ceasingthe advance of the advancing toweling comprises drawing current out ofthe motor; and said step of applying force to the toweling, via themotor, comprises providing current of a second polarity to the motor,the second polarity being reverse of the first polarity.

In a feature of this aspect, the sensor comprises a slot sensor.

Still other aspects of the invention relate to methods and operationallogic of towel dispensers as disclosed herein.

Still yet other aspects and features may be found in the incorporatedpatent publication.

In addition to the aforementioned aspects and features of the presentinvention, it should be noted that the present invention furtherencompasses the various possible combinations and subcombinations ofsuch aspects and features. Thus, for example, any aspect may be combinedwith an aforementioned feature in accordance with the present inventionwithout requiring any other aspect or feature.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more preferred embodiments of the present invention arerepresented in the drawings, wherein:

FIG. 1 is a perspective view of part of an automatic paper toweldispenser apparatus m accordance with an embodiment of the invention.

FIG. 2 is an isometric view of part of the automatic paper toweldispenser apparatus of FIG. 1 illustrating a top drive mechanism.

FIG. 3 is a perspective view of part of the automatic paper toweldispenser apparatus of FIG. 1, with the front cover removed to show thebattery holder and control circuitry.

FIG. 4 is a cross-sectional view of part of the automatic paper toweldispenser apparatus of FIG. 1, showing the spring mechanism that allowsan end of the top driven roller to move vertically, which compensatesfor both paper thickness variations and manufacturing tolerances.

FIG. 5 is a cross-sectional view of part of the automatic paper toweldispenser apparatus of FIG. 1, through the center of the device, showingthe drive roller orientation, slotted encoder wheel for measuringtoweling length, and loading door including a lower material guide inthe closed position.

FIG. 6 is another cross-sectional view of part of the automatic papertowel dispenser apparatus of FIG. 1, through the center of the device,showing the drive roller orientation, slotted encoder wheel, and loadingdoor in the open position.

FIG. 7 is a perspective view of part of an automatic paper toweldispenser apparatus in accordance with an embodiment of the invention,in which the loading door open is open and the dispenser apparatus isready to receive a roll of paper towels.

FIG. 8 is a perspective view of part of an automatic paper toweldispenser apparatus of FIG. 7, in which a roll of paper towels has beenplaced in the loading door, with a section of the toweling removed fromthe roll and draped over the roller of the loading door whereby an IRsensor at the front lip of the device can detect the toweling.

FIG. 9 is a perspective view of part of an automatic paper toweldispenser apparatus of FIG. 8, wherein the loading door has been closedwith a length of the toweling extending from the housing, whereupon thelength learn sequence is initiated.

FIG. 10 is a partial perspective view of an automatic paper toweldispenser apparatus in accordance with an embodiment of the invention,in which the automatic paper towel dispenser is installed under acabinet and a user is in the process of tearing the toweling.

FIG. 11 is a partial perspective view of an automatic paper toweldispenser apparatus in accordance with an embodiment of the invention,in which the front cover of the automatic paper towel dispenserapparatus has been removed for access to the batteries, which comprise 4D cells.

FIG. 12 is a partial perspective view of an automatic paper toweldispenser apparatus in accordance with an embodiment of the invention,in which is shown the connection of an optional 6V DC power supply forpowering the internal motor of the automatic paper towel dispenserapparatus.

FIG. 13 is an illustration of the 6V, 3.5 A, AC/DC power supply usedwith an embodiment of the invention.

FIGS. 14A and 14B collectively illustrate a block diagram representingoperational logic in accordance with an embodiment of the invention.

FIGS. 15A and 15B each represents an exemplary electronic schematicdiagram for control circuitry utilized in different embodiments ofautomatic paper towel dispenser apparatus in accordance with theinvention.

FIG. 16 is a front elevation view of part of an automatic paper toweldispenser apparatus in accordance with an embodiment of the invention.

FIG. 17 is a rear elevation view of part of the automatic paper toweldispenser apparatus of FIG. 16.

FIG. 18 is a left side elevation view of part of the automatic papertowel dispenser apparatus of FIG. 16.

FIG. 19 is a right side elevation view of part of the automatic papertowel dispenser apparatus of FIG. 16.

FIG. 20A is a top plan view of part of the automatic paper toweldispenser apparatus of FIG. 16, and FIG. 20B is the same view with thetop panel omitted.

FIG. 21 is a bottom plan view of part of the automatic paper toweldispenser apparatus of FIG. 16.

FIG. 22A is an isometric view of part of the automatic paper toweldispenser apparatus of FIG. 16, FIG. 22B is the same view with the toppanel omitted.

FIG. 23 is an isometric view of part of the automatic paper toweldispenser apparatus of FIG. 16.

FIG. 24 is an exploded, isometric View of part of the automatic papertowel dispenser apparatus of FIG. 16.

FIG. 25 is a flowchart detailing exemplary functionality of a papertowel dispenser apparatus in accordance with one or more embodiments ofthe invention.

FIGS. 26-34 illustrate an exemplary dispensing sequence for a papertowel dispenser apparatus in accordance with one or more embodiments ofthe invention.

DETAILED DESCRIPTION

As a preliminary matter, it will readily be understood by one havingordinary skill in the relevant art (“Ordinary Artisan”) that the presentinvention has broad utility and application. Furthermore, any embodimentdiscussed and identified as being “preferred” is considered to be partof a best mode contemplated for carrying out the present invention.Other embodiments also may be discussed for additional illustrativepurposes in providing a full and enabling disclosure of the full scopeof the present invention that is contemplated. Moreover, manyembodiments, such as adaptations, variations, modifications, andequivalent arrangements, will be implicitly disclosed by the embodimentsdescribed herein and fall within the scope of the present invention.

Accordingly, while the present invention is described herein in detailin relation to one or more embodiments, it is to be understood that thisdisclosure is illustrative and exemplary of the present invention, andis made merely for the purposes of providing a full and enablingdisclosure of the present invention. The detailed disclosure herein ofone or more embodiments is not intended, nor is to be construed, tolimit the scope of patent protection afforded the present invention,which scope is to be defined by the claims and the equivalents thereof.It is not intended that the scope of patent protection afforded thepresent invention be defined by reading into any claim a limitationfound herein that does not explicitly appear in the claim itself.

Thus, for example, any sequence(s) and/or temporal order of steps ofvarious processes or methods that are described herein are illustrativeand not restrictive. Accordingly, it should be understood that, althoughsteps of various processes or methods may be shown and described asbeing in a sequence or temporal order, the steps of any such processesor methods are not limited to being carried out in any particularsequence or order, absent an indication otherwise. Indeed, the steps insuch processes or methods generally may be carried out in variousdifferent sequences and orders while still falling within the scope ofthe present invention. Accordingly, it is intended that the scope ofpatent protection afforded the present invention is to be defined by theappended claims rather than the description set forth herein.

Additionally, it is important to note that each term used herein refersto that which the Ordinary Artisan would understand such term to meanbased on the contextual use of such term herein. To the extent that themeaning of a term used herein-as understood by the Ordinary Artisanbased on the contextual use of such term-differs in any way from anyparticular dictionary definition of such term, it is intended that themeaning of the term as understood by the Ordinary Artisan shouldprevail.

Furthermore, it is important to note that, as used herein, “a” and “an”each generally denotes “at least one,” but does not exclude a pluralityunless the contextual use dictates otherwise. Thus, reference to “apicnic basket having an apple” describes “a picnic basket having atleast one apple” as well as “a picnic basket having apples.” Incontrast, reference to “a picnic basket having a single apple” describes“a picnic basket having only one apple.”

When used herein to join a list of items, “or” denotes “at least one ofthe items,” but does not exclude a plurality of items of the list. Thus,reference to “a picnic basket having cheese or crackers” describes “apicnic basket having cheese without crackers”, “a picnic basket havingcrackers without cheese”, and “a picnic basket having both cheese andcrackers.” Finally, when used herein to join a list of items, “and”denotes “all of the items of the list.” Thus, reference to “a picnicbasket having cheese and crackers” describes “a picnic basket havingcheese, wherein the picnic basket further has crackers,” as well asdescribes “a picnic basket having crackers, wherein the picnic basketfurther has cheese.”

Referring now to the drawings, embodiments of the present invention arenext described. The following description of the embodiments is merelyexemplary in nature and is in no way intended to limit the invention,its implementations, or uses.

Turning now to the drawings, FIG. 1 illustrates a perspective view of anautomatic paper towel dispenser apparatus 10 in accordance with oneembodiment of the present invention. The apparatus 10 dispenses common,readily available, perforated paper towels. Furthermore, the apparatushas a learning capability, giving it the ability to detect and dispensetowels of varying lengths, including full sheets, half sheets, multiplesheets, and abnormally sized sheets. Therefore, a wide variety ofperforated towels can be used with the apparatus, including any brand orlength available at retail.

FIG. 2 is an isometric view of the apparatus 10 and FIG. 3 is aperspective view of the apparatus 10. FIG. 2 shows the top drivemechanism 12 of the towel dispenser apparatus 10. FIG. 3 shows theapparatus with the front cover 14 removed, displaying the battery holder16 and control circuitry 18. Preferably, the apparatus 10 may be poweredby either batteries 20 (as shown in FIG. 3) or an AC/DC adapter 22 (suchas the one illustrated in FIG. 13).

The apparatus 10 is intended to be mounted under kitchen cabinetry, oron the underside of any sufficiently sized shelf. Four screws 24interface with thread inserts in the main structure of the dispenser 10.Installation involves drilling four holes, positioned with a suppliedtemplate. Some features have been included to allow a level ofinstallation customization. Kitchen cabinets are constructed in a numberof ways. If a recess exists under a cabinet, the dispenser can bemounted with the supplied spacers 13. These spacers slide onto thescrews. They can be stacked and combined to achieve three height offsetsfor the dispenser.

Furthermore, if spacers are used, a gap between the dispenser andunderside of the cabinet may be visible from some angles. To addressthis aesthetic issue, trim tabs 50 have been designed into the exteriorside covers of the apparatus 10. These trim tabs 50 are simply moldedwith the side covers, and can be folded over or snapped off at scores 52(or otherwise bent) as desired in order to accommodate spacing betweenthe top panel of the apparatus and the bottom of the underside of thecabinet.

As an alternative to the spacers, it is contemplated that a bracket maybe used for mounting the dispenser.

Use of the device begins by deciding on the source of power. Four Dbatteries 20 can be used to supply the necessary 6V input, or a 6V, 3.5A AC/DC adapter 22 can be connected via a standard 5 mm input jack, asillustrated in FIG. 12. If the AC/DC adapter 22 is selected, power fromthe batteries 20 is interrupted, protecting the circuitry 18 from overvoltage damage. Specifically, plugging in the connector of the adapterinto the housing of the dispenser apparatus 100 breaks the batterycircuit, thereby preventing parallel connection of the batteries andAC/DC supply. An off the shelf DC jack with a ground interrupt loop,KOBICONN 163-MJ21-EX, provides this switching protection.

FIGS. 7-9 are photographs showing steps in a sequence of installingtoweling into an automatic paper towel dispenser apparatus 100 inaccordance with an embodiment of the invention. FIGS. 14A and 14Bcollectively illustrate a block diagram describing operational logicthat is implemented in the automatic paper towel dispenser apparatus100; and FIG. 15A is an electronic schematic diagram for controlcircuitry that may be utilized in automatic paper towel dispenserapparatus in accordance with at least one embodiment of the invention.FIG. 15B is an alternative electronic schematic diagram for controlcircuitry that may be utilized in automatic paper towel dispenserapparatus in accordance with at least one other embodiment of theinvention, wherein, inter alia, a single position sensor is utilized.

A latch mechanism is released to open apparatus 100. This latch isoperated by a sliding pull handle located on the underside of the frontsection of the dispenser. FIG. 7 shows the apparatus 100 in the openposition and ready to accept a roll of paper towels. The lower driverroller moves with the towel carrier. This feature greatly simplifiesinstallation of the toweling. In conventional dispensers, tensioningdevices and a convoluted feeding route need to be understood by theoperator. In apparatus 100, the operator simply installs a roll oftowels with the first towel draped over the lower drive roller andcloses the device. There is no requirement for the toweling to bethreaded through any path defined by rollers and tensioning devices.

Included in the rotating towel carrier subassembly is a magnet thatinterfaces with a hall-effect transducer resident on the main circuitboard. Output from the hall-effect transducer notifies the microcontroller of the position of the towel carrier door. Each time the dooris opened, the device is reset. Upon closing the door, themicrocontroller initiates a “Length Learn” program sequence.

With particular regard to the “Length Learn” program sequence, theapparatus 100 first retracts the toweling until output from the “S 1”positioning reflective IR sensor indicates that no paper is present,i.e., that a leading edge of the toweling has been sensed. Thisreflective sensor is located at the front and top of the dispensingslot. It is mounted to the main circuit board, and protrudes through anopening that keeps it flush with the dispensing slot top surface. In atleast some preferred implementations, a surface opposite the reflectivesensor includes one or more holes or openings to prevent reflections offof dispenser components from being an issue. Position of the towel'sedge has now been determined. Preferably, a known length, such as twelveinches of paper towel, is then dispensed although a greater length maybe dispensed, especially if the user desired dispensing of more than onetowel at a time.

The length of toweling that is dispensed is determined by driving themotor in the forward direction a predetermined number of encoder counts,or “Drive Length Units”. Length corresponds to counts. Counts correspondto both edges of openings in a slotted wheel axially mounted to the toproller shaft. Output from a slot type IR sensor, TT Optek OPB89IT51Z, isused by the microcontroller to count. In a preferred implementation,there are 32 counts per revolution with a 16 slot wheel.

A pause in the program, referred to as the “Tear Time Interval”, allowsan operator to interact with the dispenser. Towel length for allsubsequent dispensing is determined by tearing off a length of towel atany desired perforated position. “Tear Time Interval” concludes and thedispenser again retracts until the reflective IR sensor detects theleading edge of the toweling. While reversing, the microcontroller againuses the encoder to count openings in the slotted wheel, sometimesreferred to as an encoder pinwheel. “Retract Length Units”, reversecounts, are used to determine “Learned Towel Length”, whereupon the“Length Learn” program sequence is completed. The Learned Towel Lengthor L TL is determined by subtracting the Retract Length Units or RLUfrom the Drive Length Units or DLU.

It further will be appreciated that technology other than an encoderpinwheel may be used as an alternative for measuring the extent to whichthe toweling is extended or retracted by the motor. For example, thetechnology conventionally found in an optical mouse may be utilized,which includes a tiny camera that takes thousands of pictures per secondto determine position and speed. Conventionally, the optical mouse usesa very small light emitting diode more commonly referred to as an LEDwhich is red in color. This LED bounces light off of a mouse pad or desksurface onto a CMOS (Complementary Metal Oxide Semiconductor).

In the context of the present invention, this same technology may beused to determine the extent of the toweling that is extended orretracted. In operation, the LED produces a red light that is emittedonto the toweling surface. The light is reflected off the surface backto the CMOS sensor. The CMOS sensor sends each image that is reflectedback to a DSP (Digital Signal Processor) for analysis. Using thethousands of images (taken at hundreds of times per second) that theCMOS sends to the DSP for analysis, the DSP is able to detect bothpatterns and images and can determine if the toweling has moved, at whatdistance it has moved, and at what speed.

Yet another alternative technology includes that found in laser-basedoptical mice, which technology piggy backs off of the LED optical mouse.The laser based optical mouse works similar to the LED based opticalmouse. It uses a laser instead of a LED. The benefit is that because ituses a laser beam, the mouse can track much better, giving the userultimately better response times, tracking and the ability for such amouse to be used on even more surfaces. In the context of the presentinvention, it is believed that use of such laser technology wouldprovide greater precision and accuracy in determining the extent of thetoweling that is extended or retracted.

Furthermore, the housing in the area of the detection of the towelingsurface preferably is dark and contrasts well with the toweling so as tobetter define the leading edge of the toweling for detection, whetherthe IR, optical or laser technology is used.

After the LTL is learned, the operator engages the “Hand Wave” sensor todispense a towel. The reflective IR sensor shown in the drawings isinterfaced with through a lens located in the center of the front fasciapanel. The sensor emitter and detector are mounted directly to the maincircuit board. Therefore, they do not move with the removable fasciapanel. As a result, their placement, and proper installation of thefascia panel, is important to check for correct operation.

After the “Length Learn” sequence is completed, the dispenser's microcontroller enters a program that constantly looks at the “Hand Wave”sensor for output. Some level of ambient IR light is always present.Also, people and objects may continually pass in front of the devicewith no intention of initiating towel dispensing. Preferably, “HandWave” sensor output voltage is sampled and compared to avoid falseinitiation. The sample rate may be every 10 milliseconds, for example.

When an operator or user intends to dispense a towel, “Hand Wave” sensorvoltage is substantially higher than ambient for a determined number ofsamples. At this point the motor is driven forward the “Learned TowelLength”. To accommodate possible additional towels being desired by theuser, the program delays for one tenth of the “Tear Time Interval”, thenreviews the “Hand Wave” sensor output. If a hand is still present, thetoweling is extended an additional L TL. This additional dispensingsub-sequence will continue until a hand is no longer detected by the“Hand Wave” sensor. When a hand is no longer detected by the “Hand Wave”sensor, the “Tear Time Interval” is initiated, during which the operatoris expected to tear off the desired paper towels from the dispensedtoweling. After the “Tear Time Interval”, the motor is driven in reverseuntil the positioning sensor “S 1” again detects the leading edge (i.e.,presumed new leading edge) of the toweling.

Alternatively, the motor is driven forward the number of desired LTLs(e.g., 1 LTL, 2 L TLs, or 3 L TLs), plus a predetermined additionalextent. The predetermined extent may be, for example, a distance betweenthe point at which the leading edge of the toweling is detected by thesensor, and a point exterior of the housing and proximate to area atwhich the toweling exits the housing. In accordance with thisalternative, a line of perforations should be found each time a towel isdispensed at a point exterior of the housing and proximate the area atwhich the toweling exits the housing. As such, a small extent of thetoweling following separation of the dispensed towels will be leftextending outside of the housing and will be retracted back into thehousing to the point at which the leading edge of the toweling isdetected by the sensor. In accordance with this alternative, an operatorwill be able to clearly observe the particular line of perforationsalong which the tear is made.

Normal dispensing by the apparatus continues until all the towels on theroll have been dispensed, or until a dispensing error occurs.

All errors result in the bi-color indicator LED lighting red. Anoperator must open the device to reset the error condition. After anyerror, the “Length Learn” program will run again and the operator mustteach the dispenser the desired dispense length.

Reliable paper feeding, without a specific paper to optimize the systemaround, is not trivial. Variations in thickness, friction coefficient,strength, surface area, and cross section must all be accommodated.Moreover, paper is removed by pulling with sufficient force to break theroll at a perforation, and this force also must be accommodated.

Several features have been designed to prevent malfunction, improvepaper feed ability, and reliable operation. In particular, at leastthree main reliability features are provided in the apparatus 100 thatare intended to prevent malfunction, improve paper feed ability, andreliable operation. Furthermore, it should be understood that, whileembodiments of the invention may include only one or two-or none-ofthese features, other embodiments of the invention may include all threeof these features.

The first reliability feature of the mechanism allows the upper driveroller to travel vertically. Two springs hold the roller in its lowestposition. When the towel carrier is closed, the lower drive rollerdictates the upper drive roller's position. This addresses differenttowel thicknesses that will tend to push the upper roller to slightlydifferent positions. With the spring loaded drive roller, thicknessvariations throughout the roll are constantly accounted for. This alsoaddresses inherent manufacturing dimensional variation, withintolerances, that otherwise affects feed reliability, especially wheninjected molding with plastics.

The second reliability feature prevents unwanted movement of one or bothrollers. Both rollers in this dispenser are driven. They are directlylinked together (or directly interconnected) by a pair of axiallymounted end gears. These gears have fairly large and forgiving toothgeometry. This is important, because of the unique ability to separatethe rollers during paper installation. Opening the rollers enough forthe entire roll to pass between them separates the gears completely.They must re-mesh, without damage or perceived difficulty, when thedispenser is closed.

The third reliability feature is software based. During the “Tear TimeInterval” the motor has a percentage of the stall current applied inreverse. This applies force to the drive mechanism, preventing itsmovement, and allowing a very positive feel as the towel's perforationis broken by the user pulling on the toweling portion extending from thehousing. Indeed, even slow and consistent pull on the extended towelingdoes not further extend toweling from the dispenser due, at least inpart, to the application of reverse current.

Yet another automatic paper towel dispenser apparatus 200 in accordancewith an embodiment of the invention is illustrated in FIGS. 16A through23B. Operation and structure of apparatus 200 is similar to thosedisclosed above. Of additional note, FIG. 23A and FIG. 23B illustratethe open area within the housing, over the space for receiving a roll ofpaper towels, into which area toweling that is retracted into thehousing may be directed. Moreover, if too much toweling is retractedinto this area, the excess toweling likely falls out of the back of theapparatus, thereby avoiding possible jamming of the apparatus 200. Tothis end, the back of the housing preferably is open when the door isclosed, as shown in FIG. 23A and FIG. 23B.

Additional description of structure and functionality in accordance withone or more embodiments will now be provided, first with reference tothe exemplary flowchart of FIG. 25, and then with reference to FIGS.26-34.

In one or more embodiments, an automatic paper towel dispenser apparatusis configured to, after learning how long a paper towel of a paper towelroll is, dispense one or more paper towels via a dispensing opening.Such dispenser apparatus includes a hand wave sensor configured to sensethe wave of a user's hand. The dispenser apparatus is configured suchthat, when a firsthand wave is detected at step 1002, toweling begins tobe advanced at step 1004 by providing current to a motor assemblyconfigured to drive the dispensing of toweling.

As the toweling is advanced, a leading edge of the toweling, i.e. aleading edge of the first paper towel, is detected at step 1006 by areflective sensor the toweling travels past prior to passing through thedispensing opening. This reflective sensor preferably operates bydetermining whether emitted light is reflected by toweling, e.g. whitetoweling.

Following detection of this leading edge, an extent determined based ona learned length of toweling is advanced at step 1008. The advancing ofexactly this extent is preferably provided via use of a slot sensor. Theslot sensor comprises an emitter, a detector disposed opposite theemitter, and a rotatable disc disposed therebetween. The rotatable discincludes a plurality of slots disposed therein. As toweling is advanced,the rotatable disc rotates, and, as the slots and non-slot sections passbetween the emitter and receptor, light emitted by the emitter isintermittently received by the receptor. The slot sensor is configuredto determine, based on the intermittent reception of light by thereceptor, the amount of rotation of the rotatable disc, and thus theamount of toweling advanced. Once, following detection of the leadingedge, the desired extent of toweling based on a learned length oftoweling has been advanced, current is drawn from the motor assembly tohalt dispensing at step 1010. In at least some embodiments, upon haltingof dispensing, a perforated line separating the first paper towel from anext paper towel is disposed at, on, under, and/or proximate to thereflective sensor. In at least some other embodiments, an additionaloffset is added to or subtracted from a learned towel length such thatsuch perforated line is disposed upstream of, or downstream of, thereflective sensor.

Preferably, the dispenser apparatus is further configured such that,following halting of dispensing, a first time period begins at step1012. This time period is preferably measured by a timer, and preferablylasts around one second. At any time prior to the end of this timeperiod, a subsequent hand wave will trigger advancement of an additionalextent of toweling based on a learned length. Preferably, such asubsequent hand wave will also result in the resetting or restarting ofthe first time period, thereby providing additional time for yet anotherhand wave, although, in at least some embodiments, this is not the case.In this way, a user is able to trigger dispensing of any number of papertowels that they wish, via, for example, that number of hand waves, orby continually leaving their hand in front of the hand wave sensor untila desired number of paper towels have been dispensed. In an embodiment,during this first time period, an indicator disposed proximate the handwave sensor displays a first color, e.g. red.

Preferably, following expiration of this first time period, a secondtime period begins. This second time period is preferably also measuredby a timer, and preferably lasts around four seconds. During this secondtime period, hand waving by the user does not trigger the dispensing ofany additional paper towels. In an embodiment, during this second timeperiod, an indicator disposed proximate the hand wave sensor displays asecond color, e.g. orange.

This second time period is intended to allow a user to tear off one ormore dispensed paper towels. It will be appreciated that, when a usergoes to tear off one or more dispensed paper towels, force applied bythe user could cause the withdrawal of additional toweling from thedispenser apparatus, barring any mechanism for the prevention of suchadditional withdrawal. In an embodiment, the slot sensor is utilized incombination with the motor assembly to mitigate, or prevent, any suchwithdrawal, via the use of a “fight sequence”. Preferably, the slotsensor is utilized to determine whether additional toweling has beenwithdrawn, via the detection of rotation of the rotatable disc of theslot sensor. In the event of such rotation, current, having an oppositepolarity to that described hereinabove (sometimes referred to herein asreverse polarity current), is preferably provided to the motor assemblyto return the slot sensor to its prior position (e.g. the position itwas in prior to rotation of the slot sensor caused by a user attemptingto tear off one or more dispensed paper towels).

The second time period is represented by step 1016. Upon expiration ofthe second time period, the reflective sensor disposed proximate thedispensing opening determines whether or not toweling is sensed at step1018. If the reflective sensor senses toweling, then the toweling isretracted by providing reverse polarity current to the motor assembly atstep 1020. The toweling is preferably retracted until the reflectivesensor no longer senses toweling.

Following this, the dispenser apparatus is ready to once again detect auser's initial hand wave at step 1002.

FIGS. 26-34 illustrate an exemplary dispensing sequence for a papertowel dispenser apparatus in accordance with one or more embodiments ofthe invention.

FIG. 26 illustrates a paper towel dispenser apparatus. To dispensetoweling, a user triggers a hand wave sensor of the dispenser apparatususing their hand, as illustrated in FIG. 27. Upon detecting the user'shand via the hand wave sensor, the dispenser apparatus dispenses alearned towel length. After dispensing the learned towel length, thedispenser apparatus determines whether the user's hand is still present,or if the user has waved his hand again. If so, the dispenser apparatusdispenses an additional learned towel length. In this way, a user caneffect dispensing of multiple learned towel lengths by leaving his handin front of the hand wave sensor, as illustrated in FIGS. 28-29.

Once the user ceases triggering the hand wave sensor via their hand,then the dispenser apparatus will cease dispensing additional learnedtowel lengths. Upon this occurring, the dispenser apparatus will beginwaiting a tear time interval, thereby allowing the user to tear off oneor more sheets of dispensed toweling. FIG. 30 illustrates a user tearingoff a single sheet of dispensed toweling after dispensing a plurality ofsheets of toweling. Upon expiration of the tear time interval, thesheets that were dispensed, but not tom off by the user, are retractedback into the dispenser apparatus, as illustrated in FIGS. 31-34.

Based on the foregoing description, it will be readily understood bythose persons skilled in the art that the present invention issusceptible of broad utility and application. Many embodiments andadaptations of the present invention other than those specificallydescribed herein, as well as many variations, modifications, andequivalent arrangements, will be apparent from or reasonably suggestedherein, without departing from the substance or scope of the presentinvention.

Accordingly, while the present invention has been described herein indetail in relation to one or more preferred embodiments, it is to beunderstood that this disclosure is only illustrative and exemplary ofthe present invention and is made merely for the purpose of providing afull and enabling disclosure of the invention. The foregoing disclosureis not intended to be construed to limit the present invention orotherwise exclude any such other embodiments, adaptations, variations,modifications or equivalent arrangements, the present invention beinglimited only by the claims appended hereto and the equivalents thereof.

1. A towel dispenser, comprising: (a) a housing for receiving toweling, comprising (i) a main body, (ii) a loading door that is configured to rotate relative to the main body between, (A) a closed position, in which the housing is configured to dispense towels there from, and (B) an open position, in which the housing is configured to receive toweling therein, and (iii) a guide system that is configured to guide the toweling within the housing while towels are dispensed from the housing; (b) wherein the guide system comprises a first roller attached to the main body and having a first toothed surface, and a second roller attached to the loading door and having a second toothed surface that is configured to mesh with the first toothed surface; and (c) wherein the toothed surfaces of the first roller and the second roller mesh together when the loading door moves into the closed position from the open position and do not preclude the loading door from moving into the closed position from the open position.
 2. The towel dispenser of claim 1, wherein the housing further comprises extension walls located proximate opposite exterior sides of the housing that extends above a top side of the housing, each extension wall comprising a weakened line extending parallel to a weakened line of the other extension walls, whereby the extent above the top side at which each extension walls extends may be changed, the extent representing a distance from the underside of a fixture below which the top side of the housing is mounted when the towel dispenser is installed under the fixture.
 3. The towel dispenser of claim 2, wherein the housing further comprises a motor assembly configured to cause a leading edge of the toweling to be extended from the housing and to cause the toweling to be retracted into the housing after the leading edge has been extended; and a sensor for sensing a leading edge of the toweling during retraction of the toweling by the motor assembly; wherein the sensor is configured to cause the motor assembly to cease retracting the toweling into the housing as a function of the sensing of the leading edge of the toweling during retraction of the toweling into the housing.
 4. The towel dispenser of claim 2, wherein the loading door comprises a towel carrier having a curved surface defining a cavity configured to receive the roll of paper towels in floating engagement therewith such that the roll of paper towels rolls and slides on the curved surface during unwinding.
 5. The towel dispenser of claim 4, wherein the housing further comprises a motor assembly configured to cause a leading edge of the toweling to be extended from the housing and to cause the toweling to be retracted into the housing after the leading edge has been extended; and a sensor for sensing a leading edge of the toweling during retraction of the toweling by the motor assembly; wherein the sensor is configured to cause the motor assembly to cease retracting the toweling into the housing as a function of the sensing of the leading edge of the toweling during retraction of the toweling into the housing.
 6. The towel dispenser of claim 4, wherein the loading door comprises a towel carrier having a curved surface defining a cavity configured to receive the roll of paper towels in floating engagement therewith such that the roll of paper towels rolls and slides on the curved surface during unwinding.
 7. The towel dispenser of claim 1, wherein the first roller engages the second roller when the loading door is in the closed position.
 8. The towel dispenser of claim 1, wherein an axis of rotation of the first roller is located above and forward of an axis of rotation of the second roller when the loading door is in the closed position.
 9. The towel dispenser of claim 1, wherein the first roller extends generally alongside a compartment of the housing in which a battery is received, the compartment being accessible through a removable front cover of the housing for changing the battery.
 10. The towel dispenser of claim 1, wherein each toothed surface comprises an axially mounted end gear.
 11. The towel dispenser of claim 1, wherein the first toothed surfaces is located proximate a first end of the first roller, and wherein the second toothed surface is located proximate a first end of the second roller, the respective first ends of the first and second rollers being located proximate one another when the loading door is in the closed position.
 12. The towel dispenser of claim 1, wherein a transmission connects a motor to a second end of the first roller, the second end of the first roller being opposite to the first end of the first roller.
 13. The towel dispenser of claim 1, wherein the first end of the first roller is configured to move vertically a small extent, but the second end of the first roller is not configured to move vertically a small extent.
 14. The towel dispenser of claim 1, wherein the toothed surface of the first roller is spring biased into meshing engagement with the toothed surface of the second roller when the loading door moves into the closed position from the open position.
 15. The towel dispenser of claim 1, wherein the first end of the first roller floats relative to the main body, but the second end of the first roller is fixed relative to the main body, and wherein the toothed surface of the first roller is spring biased into meshing engagement with the toothed surface of the second roller when the loading door moves into the closed position from the open position.
 16. The towel dispenser of claim 1, wherein a belt engages the second end of the first roller for driving of the first roller by the motor.
 17. The towel dispenser of claim 1, wherein the toothed surface of the first roller is spring biased into meshing engagement with the toothed surface of the second roller when the loading door moves into the closed position from the open position.
 18. The towel dispenser of claim 1, wherein the only rollers of the guide system are the first and second rollers.
 19. The towel dispenser of claim 1, wherein the motor assembly is configured to wait a predetermined period of time after the toweling is extended exterior of the housing for grasping by a user before causing the toweling to retract into the housing and, while waiting, to retract the toweling in order to compensate for additional extension of the toweling resulting from the grasping of the toweling by the user.
 20. The towel dispenser of claim 19, wherein the motor assembly is configured, while waiting, to continuously perform the steps of (a) attempting retraction of the toweling in response to detected further extension of the toweling resulting from grasping of the toweling by the user; and (b) ceasing retraction of the toweling in response to detected retraction of the further extension of the toweling resulting from grasping of the toweling by the user. 